The andon system alerts managerial, maintenance, or other staff of a production process problem. The alert itself can be activated manually with a button or pull cord, but it can also be activated automatically by production equipment. Most Andon boards utilize three colored lights similar to a traffic signal: green (no errors), yellow or amber (problem identified, or quality check needed), and red (production stopped due to unidentified issue).
Andon System Element
Description
Implications
Key Characteristics
Examples
Applications
Visual Display
The Andon System typically includes a visual display, such as lights or digital screens, to indicate the status of a process or machine.
– Provides real-time visibility into the status of operations or processes. – Facilitates quick identification of issues or abnormalities.
– Visual indicators like colored lights or digital screens.
– Colored stack lights on a manufacturing production line. – Digital dashboard displaying machine status in a control room.
– Manufacturing: Monitor production line status. – Healthcare: Track patient flow in a hospital. – IT Operations: Monitor server status in a data center.
Alerting Mechanism
An alerting mechanism, often triggered by operators, is a core component of the Andon System. It signals when an issue or deviation occurs.
– Enables prompt response to problems, minimizing downtime or defects. – Empowers operators to take immediate action or escalate issues.
– Alarms, sirens, buzzers, or electronic notifications.
– Audible alarm when a machine malfunctions. – Flashing red light on a workstation indicating a quality issue.
– Automotive Production: Notify operators of defects on an assembly line. – Call Centers: Alert supervisors to high call volume. – Retail: Request manager assistance at checkout counters.
Standard Operating Procedures (SOPs)
The Andon System is aligned with established procedures and protocols.
– Ensures that operators follow predefined steps for issue resolution. – Provides consistency and clarity in problem-solving processes.
– Documented procedures and checklists for issue resolution.
– Step-by-step checklist for addressing machine breakdowns. – SOPs for handling customer complaints in a service center.
– Manufacturing: Guide operators in diagnosing and resolving production issues. – Customer Support: Standardize responses to customer inquiries. – Aviation: Follow protocols for handling in-flight emergencies.
Operator Involvement
Operators are actively engaged in the Andon System, responsible for initiating alerts, making decisions, and participating in issue resolution.
– Empowers front-line operators to be problem solvers. – Fosters a culture of accountability and continuous improvement.
– Trained operators who can identify issues and trigger alerts.
– Manufacturing operator pressing an Andon button to halt production. – Call center agent using an Andon system to request managerial support.
– Lean Manufacturing: Involve operators in detecting and addressing production issues. – Customer Service: Enable agents to seek assistance during complex customer interactions. – Emergency Response: Allow frontline personnel to request immediate backup.
Escalation Process
The Andon System includes an escalation process that defines how issues are escalated to higher levels of management or specialized teams.
– Ensures that critical problems receive appropriate attention and expertise. – Prevents bottlenecks by involving higher-level support when needed.
– Clearly defined escalation paths and criteria for escalation.
– Production issue escalated from the production floor to the production manager. – IT incident escalated from the help desk to a specialized support team.
– Manufacturing: Escalate equipment failures to maintenance teams. – IT Operations: Escalate critical system outages to specialized engineers. – Healthcare: Escalate patient emergencies to medical specialists.
The andon system is an aspect of lean manufacturing that alerts employees to a problem in a production process.
Lean manufacturing seeks to maximize product value while minimizing waste without sacrificing productivity. According to the Lean Enterprise Research Centre (LERC), 60% of a typical manufacturing process is waste. While the removal of waste is perhaps synonymous with lean manufacturing, the goal of the methodology is the sustainable delivery of value to the customer.
Andon is one of the principle elements of the Jidoka quality control method that is described as “intelligent automation” or “automation with a human touch”.
Jidoka was first used in 1896 by Sakichi Toyoda, who invented a textile loom that would stop automatically when it encountered a defective thread. Jidoka is a Japanese term used in lean manufacturing. The term describes a scenario where machines cease operating without human intervention when a problem or defect is discovered.
Jidoka is in turn part of the Toyota Production System (TPS) that empowers personnel to halt the production process without managerial approval if an error occurs.
The Toyota Production System (TPS) is an early form of lean manufacturing created by auto-manufacturer Toyota. Created by the Toyota Motor Corporation in the 1940s and 50s, the Toyota Production System seeks to manufacture vehicles ordered by customers most quickly and efficiently possible.
The focus of Andon is to locate the root cause of a problem and resolve it as quickly as practicable.
Once the employee has been alerted of a problem, the aim is to stop the process and prevent the error from continuing down the line.
How does the andon system work?
The word “andon” is derived from a type of Japanese lantern or light. In Toyota factories, the Andon board is a large sign that displays the status of each assembly line section.
The sign is difficult to miss and is an effective way to instantly communicate problems.
When a worker pulls the cord or pushes the button in a particular section, that section is illuminated on the Andon board and indicates a problem that requires assistance.
There may also be other visual and audio notifications such as horns and alarm bells.
Most Andon boards utilize three colored lights similar to a traffic signal:
Green
Normal assembly line operations with no errors. Work should continue as usual.
Yellow or amber
When a problem has been identified and employees must assist the operator or perform product quality checks.
Red
When production has stopped because the issue has not been rectified.
Employees should consult with the team leader or have a supervisor check the area to fix the problem before production recommences.
In the Amazon Shareholders’ Letter for 2018, Jeff Bezos analyzed the Amazon business model, and it also focused on a few key lessons that Amazon as a company has learned over the years. These lessons are fundamental for any entrepreneur, of small or large organization to understand the pitfalls to avoid to run a successful company!
When an individual contacts customer service about a product issue, the Amazon staff member can pause production if they suspect a problem with the company’s inventory.
When this occurs, the item is removed from the Amazon marketplace to stop others from encountering the same issue.
This has enabled the company to reduce the number of product returns and support requests, and Amazon has automated systems to restart production or order fulfillment once the problem has been rectified.
Andon principles are also incorporated into systems that scan for subpar customer experiences.
When Amazon Video On Demand was released, customers who experienced playback issues were issued refunds.
This system likely also exists in Amazon Prime Video.
If not properly managed, employees may over-rely on the Andon system for minor issues, causing unnecessary production stops.
Requires a Cultural Shift
Effective implementation of Andon requires a cultural shift in the organization towards continuous improvement and employee empowerment, which can be challenging.
Dependence on Employee Training and Awareness
The success of the Andon system heavily depends on the training and awareness of the employees using it.
Risk of Production Delays
While it helps in maintaining quality, the Andon system can lead to production delays if the underlying issues are not quickly resolved.
Need for Proper System Design
Incorrectly designed Andon systems can lead to confusion, miscommunication, or delayed responses to actual problems.
When to Use the Andon System
In Manufacturing Environments
The Andon system is particularly useful in manufacturing settings where quality and efficiency are critical.
For Quality Control
It is an effective tool for quality control, as it helps in identifying and addressing issues promptly.
In Process Improvement
Organizations focusing on process improvement and Lean methodologies can benefit from implementing an Andon system.
Where Immediate Response is Required
In any operational setting where immediate response to issues is necessary to prevent further complications or losses.
How to Implement the Andon System
Install Visual and Audible Alarms
Set up a system of lights or alarms that can be easily activated and seen or heard throughout the production area.
Train Employees
Conduct thorough training for employees on how to use the Andon system and the importance of immediate problem reporting.
Establish Response Protocols
Develop clear protocols for responding to Andon alerts, including who is responsible and what steps should be taken.
Empower Employees
Encourage and empower employees to use the Andon system without fear of repercussion for stopping production.
Monitor and Analyze Data
Regularly monitor the data and feedback from the Andon system to identify recurring issues and areas for process improvement.
What to Expect from Implementing the Andon System
Improved Real-Time Problem Detection
The Andon system allows for quicker detection and addressing of problems in the production process.
Enhanced Product Quality
Timely addressing of issues leads to improved overall product quality.
Increased Employee Involvement
Employees are more engaged in the process, fostering a culture of accountability and continuous improvement.
Potential Initial Slowdown
Initially, there may be a slowdown in production as employees and managers adjust to the new system.
Long-Term Efficiency Gains
Over time, the Andon system can lead to significant efficiency gains and a reduction in defects and production downtime.
Andon System Implementation at Toyota:
Description: Toyota, as part of its Toyota Production System (TPS), implemented the Andon System to empower workers and improve quality on the production line. The Andon System consists of visual signals, such as lights or electronic displays, installed at workstations to indicate when abnormalities occur in the production process.
Method: At Toyota, workers are trained to recognize abnormalities such as defects, equipment malfunctions, or safety hazards. When an issue is detected, the worker pulls a cord or presses a button to activate the Andon signal, which alerts supervisors and support staff. Production may be stopped temporarily to address the problem, and the team works collaboratively to resolve the issue before restarting production.
Implication: The implementation of the Andon System at Toyota has led to several positive outcomes:
Improved Quality: By empowering workers to stop the production line when abnormalities are detected, Toyota ensures that defects are addressed promptly, leading to higher-quality products.
Enhanced Efficiency: Rapid problem resolution reduces downtime and prevents the production of defective units, resulting in improved productivity and efficiency.
Employee Empowerment: The Andon System fosters a culture of employee involvement and continuous improvement, as workers are actively engaged in problem-solving and decision-making on the production line.
Cost Savings: By preventing the production of defective products and minimizing rework or scrap, Toyota realizes cost savings and maintains a competitive edge in the automotive industry.
Continuous Improvement: The Andon System serves as a cornerstone of Toyota’s commitment to continuous improvement, driving innovation and efficiency throughout the organization.
Key takeaways
The andon system is an aspect of lean manufacturing that alerts employees to a problem in a production process. The word “andon” is derived from a type of Japanese lantern, with Andon boards in Toyota factories displaying green, yellow, and red status lights for different sections of the assembly line.
Andon is one of the principle elements of the Jidoka quality control method which is part of the Toyota Production System (TPS). This system empowers personnel to halt the production process without managerial approval if an error occurs.
Outside of lean manufacturing, the andon system supports Amazon’s obsession with the customer and waste avoidance (frugality) mindset. Andon addresses product-related issues before they affect other buyers and also identifies subpar customer experiences across Amazon’s various services.
Key Highlights
Andon System Overview:
The Andon system is a feature of lean manufacturing used to identify and address problems within a production process.
It takes its name from a Japanese lantern and utilizes illuminated boards with color-coded lights to communicate the status of different sections of an assembly line.
Lean Manufacturing and Waste Reduction:
Andon is a fundamental element of lean manufacturing, which aims to maximize product value while minimizing waste.
Within the context of the Jidoka quality control method, Andon plays a key role in empowering employees to stop production when errors are detected, promoting both quality and efficiency.
Andon in Toyota Production System (TPS):
The Andon system is an integral part of the Toyota Production System (TPS), a renowned manufacturing philosophy.
TPS emphasizes giving employees the authority to halt production without seeking managerial approval when issues arise, fostering a culture of problem-solving and continuous improvement.
Function of Andon:
The primary function of Andon is to quickly identify the root cause of a problem within the production process and take immediate action to resolve it.
By preventing errors from progressing down the line, Andon helps maintain product quality and efficiency.
Andon System Operation:
Andon boards employ color-coded lights for visual communication: green signifies normal operation, yellow indicates a problem has been identified, and red signifies that production has been stopped.
This clear and intuitive system enables rapid identification of issues and informs employees about the current state of the production line.
Andon System at Amazon:
Amazon utilizes the Andon system not only in manufacturing but also to address customer-related issues and minimize waste.
Amazon employees have the authority to pause production if they suspect inventory-related problems, reducing returns and customer support inquiries.
The Andon principles extend to identifying subpar customer experiences across Amazon’s services, enabling timely improvements.
Key Takeaways:
The Andon system is a visual alert mechanism used in lean manufacturing to identify and address production process problems.
It is a core component of Jidoka and the Toyota Production System, empowering employees to take action when errors occur.
Amazon employs the Andon system to ensure customer satisfaction, reduce waste, and promptly address issues related to products and services.
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The andon system alerts managerial, maintenance, or other staff of a production process problem. The alert itself can be activated manually with a button or pull cord, but it can also be activated automatically by production equipment. Most Andon boards utilize three colored lights similar to a traffic signal: green (no errors), yellow or amber (problem identified, or quality check needed), and red (production stopped due to unidentified issue).
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Gennaro is the creator of FourWeekMBA, which reached about four million business people, comprising C-level executives, investors, analysts, product managers, and aspiring digital entrepreneurs in 2022 alone | He is also Director of Sales for a high-tech scaleup in the AI Industry | In 2012, Gennaro earned an International MBA with emphasis on Corporate Finance and Business Strategy.
